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3D technologies in the Formula 1 project
Implementation stories
Automotive industry
Author: Yakov Bondarev
Author: Yakov Bondarev
R&D partnership | The ever-improving car | Quick design check | New possibilities of using wind tunnel | High speed and precision of parts manufacturing | New directions of development
Formula 1 racing is a technical sport based on continuous innovation and requires high reliability from cars.
Racing teams, including Renault Sport Formula One, are constantly striving to match and exceed the ever-improving results of the leaders. In this sport, the research and development process never stops, and technical partnerships are essential for an organization to achieve its goals. Renault Sport Formula One's collaboration with 3D Systems accelerates the development process and drives innovation at every stage, from wind tunnel and wind tunnel testing to the production of reliable finished parts. nine0003
Renault Sport Formula One team breaks new ground for innovation through R&D partnership with 3D Systems
“Race after race, more and more complex composites and aerospace alloys are being used, rigorously selected in research and development labs,” explains Renault Sport Formula One Technical Director Nick Chester. “At the end of every racing season, we expect our car to be more than a second per lap faster than it was at the beginning, and our technical partners are just as ruthlessly selected.
We're not interested in relationships that don't help us improve our performance." nine0003
The yardstick of ongoing innovation and strong collaboration explains the Renault Sport Formula One team's choice of 3D Systems and its 3D printing technology suite.
R&D partnership
Based in Enstone, UK, the Renault Sport Formula One team has been using 3D Systems technology since 1998. She was one of the first to use 3D printing for prototyping and closely monitored the development of this technology. Early on, the technology was used to test designed parts for functional and dimensional requirements, and to make jigs and fasteners for precise assembly. As the partnership between the two companies developed, 3D Systems engineers helped the Renault Sport Formula One team understand and use their existing capabilities, materials and methodologies. That the team was able to keep their wind tunnel loaded is a testament to the positive impact of the partnership with 3D Systems and the development of innovative automotive parts using 3D die-casting and 3D metal printing (DMP).
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3D Systems laser stereolithography technology enables Renault Sport Formula One team to respond quickly to technical challenges
“The support provided by 3D Systems has also evolved as our collaboration has expanded,” explained Mr. Chester. “Looking back, as materials properties improved, the team sought to expand the range of applications for fast manufacturing materials to more complex engineering problems. The number of automotive components produced using additive manufacturing is increasing every year, bringing significant benefits to the team in terms of application flexibility and reduced production time and costs.” nine0003
Among the 3D Systems installations currently used by Renault Sport Formula One are six stereolithographic 3D printers and three selective laser sintering (SLS) machines. Materials are used ranging from Accura® for fixtures and fasteners, burnout models and wind tunnel parts to DuraForm® PA and DuraForm GF for car-mounted parts such as electrical junction boxes and air-cooling ducts.
From material suitability testing to part design optimization, the partnership between Renault Sport Formula One and 3D Systems ensures the best possible results both on and off the race track. nine0003
Continuous improvement car
Each year, the Renault Sport Formula One team designs and builds a new car that takes into account changes in the rules and follows a natural cycle of R&D to improve the performance of the car. As an example of the challenges that the changes to the Formula 1 rules entail, are the 2017 innovations allowing heavier larger tires, a wider front wing, a lower and wider rear wing and a taller diffuser. This means that parts from 2016 could not be reused in 2017. nine0003
As soon as the racing season begins, the tension only grows: sometimes there is only a week between races to make technical changes. From dedicated racetracks to rough and twisty street tracks, every race presents engineers with new challenges in terms of track architecture, climate and asphalt type.
The team prepares for the unique features of each track and uses all the time in the small gaps between races to bring the fruits of research into cars and equipment. Clearly, the speed and accuracy of 3D printing is of great value when preparing for new races. “The car is improving every day during the racing season,” says Patrick Warner, Lead Digital Manager for Renault Sport Formula One. “We need new components at every track, and the benefits of additive manufacturing are becoming ever more relevant.” nine0003
TASK
- Accelerate the R&D process in the automotive industry and promote innovation in a constantly changing environment.
SOLUTION
- 3D Systems complete solutions from printers and materials to application experience.
RESULTS
- Increased Efficiency: A small group of engineers were able to produce hundreds of parts a week for wind tunnel testing.
nine0044 - Produce complex automotive parts in hours, not weeks, with SLA and SLS technologies.
- Making more innovative parts using 3D printed die-cast patterns.
- Assuring assembly quality by designing and manufacturing precision fixtures and fasteners that would not be possible or would be too time consuming with conventional technology. nine0044
- Opening new possibilities for the development of innovative 3D printed parts for testing and mounting on race cars.
Quick design check
Rapid prototyping using 3D printing was immediately demonstrated in Formula 1 racing, where the parts installed inside the car are densely packed and limited by the contours of the aerodynamic skin. The Renault Sport Formula One team's aerodynamicists quickly realized the potential of 3D printing to validate functional and dimensional requirements based on the complexity of parts produced by 3D Systems. As a result, the use of 3D technologies has grown rapidly, from rapid prototyping to the production of models for aerodynamic testing.
nine0003
3D-printed burn-out casting patterns enable fast production of large metal parts of great complexity
Aerodynamic testing is an experience-based science,” Warner explains. “We develop and compare new ideas and identify future areas of work. The more ideas we can compare and evaluate, the more successful the races will be." In terms of parts quality, equipment life and performance, SLA technology has proven indispensable for the racing team. nine0003
New ways to use wind tunnel
In recent years, the aerodynamics group within the Renault Sport Formula One racing team has grown significantly and now has 120 employees, including aerodynamicists, technicians and modellers. According to Warner, the development of this area was largely due to the increased use of additive manufacturing technologies from 3D Systems. As one of the main advantages of 3D Systems technology, he points to the ability to build complex internal channels in aerodynamic test models, as well as the ability to collect more pressure readings.
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“The model wind tunnel test car has a complex network of pressure sensors,” says Warner. “Before the advent of SLA technology, sensors were installed by drilling pressure tapping holes in metal and carbon fiber parts. The ability we now have to fabricate complex solids with extensive internal channels has revolutionized sensor placement and dramatically increased the number of sensors. It's an aerodynamicist's dream come true." nine0003
The wind tunnel test alone requires 600 parts per week to be 3D printed, Warner estimates, all of which is done by just five digital engineers.
“Using traditional technologies, we could not even dream of such a result,” notes Patrick Warner. “We would need a machine shop the size of a small town. Thanks to 3D Systems, we have a one-stop shop. We have the right equipment, the right materials, and the experience of application engineers who can get to work immediately.” nine0003
High speed and accuracy of parts manufacturing
Metal 3D printing partnership with 3D Systems makes it possible to create innovative automotive components
In terms of performance and efficiency, 3D printing has greatly increased the Renault Sport Formula One racing team's ability to respond to the new challenges posed by the ever-changing rules of Formula One racing.
With SLA and SLS technologies, complex fixtures and fasteners, fluid dynamic parts and automotive components can be produced in hours rather than weeks, making 3D technology ideal for solving Formula 1 racing logistical challenges. nine0003
In addition to the huge number of parts tested in the wind tunnel every month, the Renault Sport Formula One team manufactures a number of racing car parts directly. “3D Systems technologies have provided the foundation for a new, efficient manufacturing process that has enabled us to reduce both cycle times and costs, bringing invaluable benefits to the entire team,” said Rob White, CEO of Renault Sport Formula One. - On the one hand, we appreciate the opportunity to test several variants of the same part in a wind tunnel. On the other hand, we see how the number of parts in the car made by selective laser sintering is growing every year.” nine0003
3D printing helps the team create lighter parts that increase the speed and fuel efficiency of the car, as well as conduct accurate and informative consumption tests to improve engine performance and reduce wear.
The finished design, along with the bill of materials, is sent to the digital technology team to manufacture the part. Thanks to SLA and SLS technologies, complex automotive components can be produced faster than ever, in some cases the part is ready for inspection even before the drawings are completed. nine0003
3D-printed diecast diecast models are also increasingly being used by the racing team for products such as transmission and suspension parts, removing restrictions on the level of complexity of parts and allowing the team's engineers to be more creative in their design. The accuracy of the SLA technology reduces the time required for the manufacture of casting patterns and machining of finished castings.
New directions of development
The benefits of 3D Systems technology, experience and services are closely linked to the key priorities of the Renault Sport Formula One team, such as innovation, efficiency, maximum precision and precision. For Bob Bell, CTO of Renault Sport Formula One, 3D Systems is more than just a technology provider: the two companies have developed a true partnership that delivers results today and creates huge potential for the future.
“Our partnership with 3D Systems over the past two decades has greatly increased productivity and efficiency,” says Bell. “It opened up new possibilities that I believe will only expand in the future.” nine0003
Translation from English. The original of this material is on the 3D Systems website.
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Article published on 11/10/2017, updated on 05/14/2021
3D printing in the design and manufacture of Formula 1 cars
News
Stratasys has published several examples of the use of branded 3D printers in the production of parts for Formula 1 racing cars.
The agreement between the American manufacturer of 3D printers and the British team McLaren Racing became known in January this year.
Stratasys has provided the stable with access to several industrial FDM and PolyJet deposition machines. Within a few months, a number of prototypes and several final 3D printed components were produced, which were used in the design of the new McLaren Honda MCL32 cars.
The first functional 3D printed component was a bracket for mounting hydraulic lines. The part is made of nylon, and direct additive manufacturing reduced the production time by about two weeks. nine0003
The connector for connecting to the radio station is printed on a Stratasys J750 photopolymer 3D printer, capable of combining materials of different colors and with different physical and mechanical properties. The part in the illustration was used during the first race of the current season in Australia.
And this part was used to make brake cooling pipes. The model was printed with ST-130 Soluble Resin and then wrapped in carbon fiber composite. The composite was fired in an autoclave, after which the polymer model was dissolved. nine0003
The 3D printed part in the illustration above was used as a mold tool to make the anti-wing movable section. It took about three days to create a part 90 cm long from heat-resistant ULTEM 1010.
Finally, a 3D printed yoke used during the design stage, with movable switches and buttons so that pilots can fully appreciate the convenience of the prototype.
“We're constantly improving our cars, so the ability to quickly test new designs is essential in the effort to lighten car designs and, more importantly, increase the number of tangible, useful modifications that enhance car performance. If we can bring new improvements to the design of cars at least one stage earlier, this will already play a key role in the competitiveness of the McLaren MCL32 on the track,” said Neil Oatley, Director of Design at McLaren Racing.
